Conversions (4WD to AWD, etc) 91 Explorer

[Ryuske]

I looked around for a while trying to find some information about the costs/etc for this, but couldn't find anything Explorer-specific.

So basically I want to convert my 91 Explorer to AWD and a manual. I realize this is expensive and not really that practical (I.E it's better to buy a car that already has these things). But I plan on keeping this truck for at least another 10 years, and it only was 83k miles on the original engine. And since these parts are at least a little intertwined I figured it would be better to do both at the same time.

I'm not 100% sure it's possible to convert an older Explorer to AWD though. So basically I was wondering if anyone could give a basic cost, and where I'd go about finding the parts to do this conversion (if possible, if not then just the one that is possible).

Thanks for the help!

 

[mr cribb]

I looked around for a while trying to find some information about the costs/etc for this, but couldn't find anything Explorer-specific.

So basically I want to convert my 91 Explorer to AWD and a manual. I realize this is expensive and not really that practical (I.E it's better to buy a car that already has these things). But I plan on keeping this truck for at least another 10 years, and it only was 83k miles on the original engine. And since these parts are at least a little intertwined I figured it would be better to do both at the same time.

I'm not 100% sure it's possible to convert an older Explorer to AWD though. So basically I was wondering if anyone could give a basic cost, and where I'd go about finding the parts to do this conversion (if possible, if not then just the one that is possible).

Thanks for the help!

Main question why do you need it to be this way? The AWD option was available in the gen 2's.

The manual conversion has been done, try looking in the transmission section for that specific conversion.

 

[Ryuske]

Well I don't "need" either one to be done. However, I live where we get a lot of snow in the winter, and I really don't like the mechanical concepts behind 4WD compared to AWD. I find AWD to be much better and much more efficient as far as traction control goes.

As for the whole manual thing, I just don't like having an auto. It's so boring.

Thanks for the response though, I'll definitely check out the transmission section.

 

[mr cribb]

Well I don't "need" either one to be done. However, I live where we get a lot of snow in the winter, and I really don't like the mechanical concepts behind 4WD compared to AWD. I find AWD to be much better and much more efficient as far as traction control goes.

As for the whole manual thing, I just don't like having an auto. It's so boring.

Thanks for the response though, I'll definitely check out the transmission section.

Okay makes sense. For simplicity I'd have a manual hub/ manual shift t-case set up.

I think regular 4wd would be better JMO though... I lived in Upstate NY for 4 years, had a few 4wd's, but never had an AWD though.

I totally get the dislike auto thing--- I agree 100%, hence why mine is manual.

 

[FIND]

swap to manual hubs/ leave them locked and put an AWD transfer case on from a second gen. Done

 

[Glen4X4]

swap to manual hubs/ leave them locked and put an AWD transfer case on from a second gen. Done

Not that simple, awd t-case does not bolt up to the 4.0 transmission and you wouldn't want to have hubs unlocked with awd or the truck could roll away.

Now you can swap the v8 drive-train from the 2nd Gen but as far as having a manual trans that is going to require a good bit more work to make it work you would need the trans from an F-150 and they did not offer awd so then you will need to research to see if that transmission has the same bolt pattern as the 4R70W that the V8 Ex came with.

 

[FIND]

huh, shoot, I thought the transfer cases' flanges were the same. I guess one would have to machine a housing for the tail to match. That is more expensive than that kind of project could ever be worth.

 

[snoranger]

huh, shoot, I thought the transfer cases' flanges were the same. I guess one would have to machine a housing for the tail to match and make a custom output shaft so the spline count would match. That is more expensive than that kind of project could ever be worth.

Fixed it for you.

 

[Ryuske]

So, since I can't get a bolt-on AWD & Manual conversion, I'll just do the manual as that seems to be pretty "bolt-on"-ish xD

So, to do this, what parts would I need? And would I need to get this from a 2nd gen, or could I get it from one of the first gens? I was looking at another thread, and it was saying I didn't really need to buy anything new, I could I just pull it off one from a pick-n-pull or whatever.

 

[mr cribb]

So, since I can't get a bolt-on AWD & Manual conversion, I'll just do the manual as that seems to be pretty "bolt-on"-ish xD

So, to do this, what parts would I need? And would I need to get this from a 2nd gen, or could I get it from one of the first gens? I was looking at another thread, and it was saying I didn't really need to buy anything new, I could I just pull it off one from a pick-n-pull or whatever.

Buy the slave cylinder new.... buy a motorcraft one save yourself the headache, it has been said many times the parts store slave cylinders are inferior. They are mostly Chinese and leak after installation. Since the slave is an internal setup (meaning you have to pull the trans to replace it) you're better off buying a motorcraft one.

There is a vendor on here by the name of fordsvtparts... pm him he gives forum members a discount. I got mine from him for 140 shipped. Local dealer wanted 190-210 for a motorcraft slave cylinder.

What parts do you need? Other than the obvious.... clutch master cylinder and lines, salve cylinder, clutch pedal, brake pedal from manual trans truck, and the obvious... the transmission. You could use a 5 speed from a gen 2 truck, there were more updates to the trans over the 1st gen, I believe it's recommended. Honestly if you could get your hands on a whole ranger w/ a 4.0 5 speed you could swap all that you need... if you use a ranger don't use a 2.3 5 speed because the trans is different. I "think" a 3.0 v6 5 speed will work, but don't quote me on that.


There may be a few other nickel and dime things... maybe someone else could chime in and help out.

There is a member on here by the name of foxracin who did this exact swap, find his thread I believe he calls it "the sploder" it's linked in his signature, so if you find any post by him you should be able to find what I'm talking about. He has pics, and lots of them regarding the swap.

 

[coco944x4s]

3.0 has its own special bellhousing, will have to be from a 4.0 truck.

 

[mr cribb]

3.0 has its own special bellhousing, will have to be from a 4.0 truck.

good to know... thanks for clearing that up.

 

[snoranger]

Parts needed:
Trans and bolts
Flywheel and bolts
clutch and bolts
NEW slave cyl.
New master cyl.
Hydro line (there are 2 different connectors. IIRC its '93+, or '92 down)
Computer (this is a debated subject, some people say its fine with the auto computer)
Pedals (1st gen Ex, 1st or 2nd gen Ranger/BII)
clutch position switch
Man trans harness (not NEEDED, there are ways around that, but highly recommended.)
Shifter, boot, and bezel

Other parts recommended for factory appearance, but not 100% needed:
Manual column
PRNDL blank plate (in gauge cluster)


There may be some stuff I missed. The last time i did the swap was 5+ years ago.

 

[Glen4X4]

Don't forget you could also get an M5OD from a 2.9 BII they share the same bolt pattern and believe that first gear is a little lower than the Explorer M5OD. But like said the 2nd Gen trans is suppose to be a little stronger than the BII and 1st gen trans.

 

[FIND]

Fixed it for you.

The spline count is different too? What about from the 5 speed on an f150?

 

[snoranger]

The spline count is different too? What about from the 5 speed on an f150?

F150s and v8 explorers use the common Ford 4x4 31 spline output shaft and 6 bolt round pattern. At least Ford figured out to keep 1 thing the same across the board.